Process for producing alpha-olefin polymer

Abstract: A catalyst for olefin polymerization is provided which comprises, as the components, a) a metallocene compound, b) an ionizing ionic compound, c) an organoaluminum compound, and d) a Lewis base compound. This catalyst has a stable active species and improves productivity of an olefin polymer without deterioration of the catalytic activity.

Description: The present invention relates to a catalyst for producing an α-olefin polymer comprising a metallocene, an organoaluminum compound, an ionizing ionic compound, and a Lewis base compound. The present invention also relates to a process for producing an α-olefin polymer employing the above catalyst. For polymerization of olefins, special active catalysts are known which comprise combination of a cyclopentadienyl derivative of a metal such as titanium, zirconium, and hafnium (Group 4B of Periodic Table) with aluminoxane. This type of catalyst is not used practically in commercial production of olefin polymers mainly because of the following disadvantages: the aluminoxane cannot readily be synthesized with high reproducibility, and therefore preparation of the catalyst and production of the polymers cannot be conducted with sufficient reproducibility; and aluminoxane is required to be used in a high ratio to the transition metal compound to achieve sufficient catalyst activity although the raw material of aluminoxane, e.g., trimethylaluminum, is expensive. To offset the disadvantages, ionic metallocene catalysts are reported. JP-A-3-207704 discloses an ionic metallocene compound prepared by reacting a metallocene compound with an ionizing ionic compound. WO92/01723 discloses an α-olefin polymerization process employing a catalyst system prepared by reacting a halogenated metallocene compound with an organometallic compound and further bringing the product into contact with an ionizing ionic compound, the catalyst system having sufficient catalytic activity. EP-A-513 380 describes a catalyst comprising a transition metal compound, a compound capable of forming an ionic complex when reacted with a transition metal compound and an organoaluminum compound. The addition of a Lewis base compound as is described in this invention is not disclosed in this prior art. The catalyst system employing an ionizing ionic compound, which has a high initial activity, loses its activity with progress of polymerization, disadvantageously. It is the object of the present invention to provide a catalyst for polymerizing olefins exhibiting improved productivity of polymers. This object could be achieved on the basis of the finding that a catalyst prepared by reacting an ionic metallocene catalyst with a Lewis base compound has a stable catalytic species, and exhibits improved productivity of polymers without deterioration of the catalytic activity. The present invention provides a catalyst for polymerization of olefins, comprising a) a metallocene compound, b) an ionizing ionic compound, c) an organoaluminum compound, and d) a Lewis base compound: a) the metallocene compound being represented by General Formula (1) or (2): where Cp 1 , Cp 2 , Cp 3 and Cp 4 are independently a substituted or unsubstituted cyclopentadienyl, indenyl, or fluorenyl group; R 1 is a substituted or unsubstituted alkylene, dialkylsilanediyl, dialkylgermanediyl, alkylphosphinediyl, or alkylimino group, and R 1 links Cp 1 with Cp 2 by bridging; M is a titanium atom, a zirconium atom, or a hafnium atom; and R 2 , R 3 , R 4 and R 5 are independently a hydrogen atom, a halogen atom, a hydrocarbon group of 1 to 12 carbon atoms, an alkoxy group of 1 to 12 carbon atoms, or an aryloxy group; b) the ionizing ionic compound being a compound which is capable of changing the above metallocene compound (a) into a cationic metallocene compound and does not react further with the formed cationic metallocene compound; c) the organoaluminum compound being represented by General Formula (3): where R 6 , R 6' , and R 6" are independently a hydrogen atom, a halogen atom, an amino group, an alkyl group, an alkoxy group, or an aryl group, and at least one of R 6 , R 6' , and R 6" is an alkyl group; d) the Lewis base compound being capable of donating an electron to the formed cationic metallocene compound. The present invention also provides a process for producing an α-olefin polymer by polymerizing an α-olefin in the presence of the above catalyst. The metallocene compound (a) employed in the present invention is represented by General Formula (1) or (2). Specific examples thereof include: bis(cyclopentadienyl)titanium dichloride, bis(cyclopentadienyl)zirconium dichloride, bis(cyclopentadienyl)hafnium dichloride, bis(methylcyclopentadienyl)titanium dichloride, bis(methylcyclopentadienyl)zirconium dichloride, bis(methylcyclopentadienyl)hafnium dichloride, bis(butylcyclopentadienyl)titanium dichloride, bis(butylcyclopentadienyl)zirconium dichloride, bis(butylcyclopentadienyl)hafnium dichloride, ethylenebis(indenyl)titanium dichloride, ethylenebis (indenyl)zirconium dichloride, ethylenebis(indenyl)hafnium dichloride, dimethylsilanediylbis(2,4,5-trimethylcyclopentadienyl)titanium dichloride, dimethylsilanediylbis(2,4,5-trimethylcyclopentadienyl) zirconium dichloride, dimethylsilanediylbis(2,4,5-trimethylcyclopentadienyl)hafnium dichloride, dimethylsilanediylbis(2,4-dimethylcyclopentadienyl)titanium dichloride, dimethylsilanediylbis(2,4-dimethylcyclopentadienyl)zirconium dichloride, dimethylsilanediylbis(2,4-dimethylcyclopentadienyl)hafnium dichloride, dimethylsilanediylbis(3-methylcyclopentadienyl)titanium dichloride, dimethylsilanediylbis (3-methylcyclopentadienyl)zirconium dichloride, dimethylsilanediylbis (3-methylcyclopentadienyl)hafnium dichloride, dimethylsilanediylbis (4-t-butyl-2-methylcyclopentidienyl)titanium dichloride, dimethylsilanediylbis (4-t-butyl-2-methylcyclopentadienyl)zirconium dichloride, dimethylsilanediylbis (4-t-butyl-2-methylcyclopentadienyl)hafnium dichloride, diethylsilanediylbis(2,4,5-trimethylcyclopentadienyl)titanium dichloride, diethylsilanediylbis(2,4,5-trimethylcyclopentadienyl)zirconium dichloride, diethylsilanediylbis(2,4,5-trimethylcyclopentadienyl)hafnium dichloride, diethylsilanediylbis(2,4-dimethylcyclopentadienyl)titanium dichloride, diethylsilanediylbis(2,4-dimethylcyclopentadienyl)zirconium dichloride, diethylsilanediylbis(2,4-dimethylcyclopentadienyl)hafnium dichloride, diethylsilanediylbis(3-methylcyclopentadienyl)titanium dichloride, diethylsilanediylbis(3-methylcyclopentadienyl)zirconium dichloride, diethylsilanediylbis(3-methylcyclopentadienyl)hafnium dichloride, diethylsilanediylbis(4-t-butyl-2-methylcyclopentadienyl)titanium dichloride, diethylsilanediylbis(4-t-butyl-2-methylcyclopentadienyl)zirconium dichloride, diethylsilanediylbis(4-t-butyl-2-methylcyclopentidienyl)hafnium dichloride, isopropylidene(cyclopentadienyl)(fluorenyl)titanium dichloride, isopropylidene(cyclopentadienyl)(fluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl)(fluorenyl)hafnium dichloride, diphenylmethylene(cyclopentadienyl)(fluorenyl)titanium dichloride, diphenylmethylene(cyclopentadienyl)(fluorenyl)zirconium dichloride, diphenylmethylene(cyclopentadienyl)(fluorenyl)hafnium dichloride, methylphenylmethylene(cyclopentadienyl)(fluorenyl)titanium dichloride, methylphenylmethylene(cyclopentadienyl)(fluorenyl)zirconiun dichloride, methylphenylmethylene(cyclopentadienyl)(fluorenyl)hafnium dichloride, isopropylidene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)titanium dichloride, isopropylidene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)zirconium dichloride, isopropylidene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride, diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)titanium dichloride, diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)zirconium dichloride, diphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride, methylphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)titanium dichloride, methylphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)zirconium dichloride, methylphenylmethylene(cyclopentadienyl)(2,7-di-t-butylfluorenyl)hafnium dichloride, isopropylidenebis(cyclopentadienyl)titanium dichloride, isopropylidenebis(cyclopentadienyl)zirconium dichloride, isopropylidenebis(cyclopentadienyl)hafnium dichloride, diphenylmethylenebis(cyclopentadienyl)titanium dichloride, diphenylmethylenebis(cyclopentadienyl)zirconium dichloride, diphenylmethylenebis(cyclopentadienyl)hafnium dichloride, methylphenylmethylenebis(cyclopentadienyl)titanium dichloride, methylphenylmethylenebis(cyclopentadienyl)zirconium dichloride, methylphenylmethylenebis(cyclopentadienyl)hafnium dichloride, isopropylidene(cyclopentadienyl)(tetramethylcyclopentadienyl)titanium dichloride, isopropylidene(cyclopentadienyl)(tetramethylcyclopentadienyl)zirconium dichloride, isopropylidene(cyclopentadienyl)(tetramethylcyclopentadienyl)hafnium dichloride, diphenylmethylene(cyclopentadienyl)(tetramethylcyclopentadienyl)titanium dichloride, diphenylmethylene(cyclopentadienyl)(tetramethylcyclopentadienyl)zirconium dichloride, diphenylmethylene(cyclopentadienyl)(tetramethylcyclopentadienyl)hafnium dichloride, isopropylidenebis(indenyl)titanium dichloride, isopropylidenebis(indenyl)zirconium dichloride, isopropylidenebis(indenyl)hafnium dichloride, diphenylmethylenebis(indenyl)titanium dichloride, diphenylmethylenebis(indenyl)zirconium dichloride, diphenylmethylenebis(indenyl)hafnium dichloride, methylphenylmethylenebis(indenyl)titanium dichloride, methylphenylmethylenebis(indenyl)zirconium dichloride, methylphenylmethylenebis(indenyl)hafnium dichloride, ethylene bis(tetrahydroindenyl) titanium dichloride, ethylene bis(tetrahydroindenyl) zirconium dichloride, ethylene bis(tetrahydroindenyl) hafnium dichloride, dimethylsilanediyl bis (indenyl) titanium dichloride, dimethylsilanediyl bis (indenyl) zirconium dichloride, dimethylsilanediyl bis (indenyl) hafnium dichloride, dimethylsilanediyl bis(2-methylindenyl) titanium dichloride, dimethylsilanediyl bis(2-methylindenyl) zirconium dichloride, dimethylsilanediyl bis(2-methylindenyl) hafnium dichloride, bis(indenyl) titanium dichloride, bis(indenyl) zirconium dichloride, bis(indenyl) hafnium dichloride, bis(cyclopentadienyl) titanium dichloride, bis(cyclopentadienyl) zirconium dichloride and bis(cyclopentadienyl) hafnium dichloride. The metallocene compounds are not limited thereto. The ionizing ionic compound (b) is exemplified by: tri(n-butyl)ammonium tetrakis(p-tolyl)borate, tri(n-butyl)ammonium tetrakis(m-tolyl)borate, tri(n-butyl)ammonium tetrakis(2,4-dimethyl)borate, tri(n-butyl)ammonium tetrakis(3,5-dimethylphenyl)borate, tri(n-butyl)ammonium tetrakis(pentafluorophenyl)borate, N,N-dimethylanilinium tetrakis(p-tolyl)borate, N,N-dimethylanilinium tetrakis(m-tolyl)borate, N,N-dimethylanilinium tetrakis(2,4-dimethylphenyl)borate, N,N-dimethylanilinium tetrakis(3,5-dimethylphenyl)borate, N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate, triphenylcarbenium tetrakis(p-tolyl)borate, triphenylcarbenium tetrakis(m-tolyl)borate, triphenylcarbenium tetrakis(2,4-dimethylphenyl)borate, triphenylcarbenium tetrakis(3,5-dimethylphenyl)borate, triphenylcarbenium tetrakis(pentafluorophenyl)borate, tropylium tetrakis(p-tolyl)borate, tropylium tetrakis(m-tolyl)borate, tropylium tetrakis(2,4-dimethylphenyl)borate, tropylium tetrakis(3,5-dimethylphenyl)borate, tropylium tetrakis(pentafluorophenyl)borate, lithium tetrakis(pentafluorophenyl)borate, lithium tetrakis(phenyl)borate, lithium tetrakis(p-tolyl)borate, lithium tetrakis(m-tolyl)borate, lithium tetrakis(2,4-dimethylphenyl)borate, lithium tetrakis(3,5-dimethylphenyl)borate, lithium tetrafluoroborate, sodium tetrakis(pentafluorophenyl)borate, sodium tetrakis(phenyl)borate, sodium tetrakis(p-tolyl)borate, sodium tetrakis(m-tolyl)borate, sodium tetrakis(2,4-dimethylphenyl)borate, sodium tetrakis(3,5-dimethylphenyl)borate, sodium tetrafluoroborate, potassium tetrakis(pentafluorophenyl)borate, potassium tetrakis(phenyl)borate, potassium tetrakis(p-tolyl)borate, potassium tetrakis(m-tolyl)borate, potassium tetrakis(2,4-dimethylphenyl)borate, potassium tetrakis(3,5-dimethylphenyl)borate, potassium tetrafluoroborate, tri(n-butyl)ammonium tetrakis(p-tolyl)aluminate, tri(n-butyl)ammonium tetrakis(m-tolyl)aluminate, tri(n-butyl)ammonium tetrakis(2,4-dimethyl)aluminate, tri(n-butyl)ammonium tetrakis(3,5-dimethylphenyl)aluminate, tri(n-butyl)ammonium tetrakis(pentafluorophenyl)aluminate, N,N-dimethylanilinium tetrakis(p-tolyl)aluminate, N,N-dimethylanilinium tetrakis(m-tolyl)aluminate, N,N-dimethylanilinium tetrakis(2,4-dimethylphenyl)aluminate, N,N-dimethylanilinium tetrakis(3,5-dimethylphenyl)aluminate, N,N-dimethylanilinium tetrakis(pentafluorophenyl)aluminate, triphenylcarbenium tetrakis(p-tolyl)aluminate, triphenylcarbenium tetrakis(m-tolyl)aluminate, triphenylcarbenium tetrakis(2,4-dimethylphenyl)aluminate, triphenylcarbenium tetrakis(3,5-dimethylphenyl)aluminate, triphenylcarbenium tetrakis(pentafluorophenyl)aluminate, tropylium tetrakis(p-tolyl)aluminate, tropylium tetrakis(m-tolyl)aluminate, tropylium tetrakis(2,4-dimethylphenyl)aluminate, tropylium tetrakis(3,5-dimethylphenyl)aluminate, tropylium tetrakis(pentafluorophenyl)aluminate, lithium tetrakis(pentafluorophenyl)aluminate, lithium tetrakis(phenyl)aluminate, lithium tetrakis(p-tolyl)aluminate, lithium tetrakis(m-tolyl)aluminate, lithium tetrakis(2,4-dimethylphenyl)aluminate, lithium tetrakis(3,5-dimethylphenyl)aluminate, lithium tetrafluoroaluminate, sodium tetrakis(pentafluorophenyl)aluminate, sodium tetrakis(phenyl)aluminate, sodium tetrakis(p-tolyl)aluminate, sodium tetrakis(m-tolyl)aluminate, sodium tetrakis(2,4-dimethylphenyl)aluminate, sodium tetrakis(3,5-dimethylphenyl)aluminate, sodium tetrafluoroaluminate, potassium tetrakis(pentafluorophenyl)aluminate, potassium tetrakis(phenyl)aluminate, potassium tetrakis(p-tolyl)aluminate, potassium tetrakis(m-tolyl)aluminate, potassium tetrakis(2,4-dimethylphenyl)aluminate, potassium tetrakis(3,5-dimethylphenyl)aluminate and potassium tetrafluoroaluminate. However, the ionizing ionic compound is not limited thereto in the present invention. The organic aluminum compound (c) employed in the present invention is a compound represented by General Formula (3), and exemplified specifically by trimethylaluminum, triethylaluminum, triisopropylaluminum, diisopropylaluminum chloride, isopropylaluminum dichloride, tributylaluminum, triisobutylaluminum, diisobutylaluminum chloride, isobutylaluminum dichloride, tri(t-butyl)aluminum, di(t-butyl)aluminum chloride, t-butylaluminum dichloride, triamylaluminum, diamylaluminum chloride and amylaluminum dichloride. The compound is not limited thereto. The Lewis base compound (d) employed in the present invention is a compound capable of donating an electron to the formed cationic metallocene compound, and exemplified specifically by esters such as methyl formate, ethyl formate, butyl formate, isobutyl formate, pentyl formate, methyl acetate, ethyl acetate, propyl acetate, isopropyl acetate, butyl acetate, isobutyl acetate, pentyl acetate, isopentyl acetate, hexyl acetate, cyclohexyl acetate, benzyl acetate, 3-methoxybutyl acetate, 2-ethylbutyl acetate, 3-ethylhexyl acetate, 3-methoxybutyl acetate, methyl propionate, ethyl propionate, butyl propionate, isopentyl propionate, methyl butyrate, ethyl butyrate, butyl butyrate, isopentyl butyrate, isobutyl isobutyrate, ethyl isovalerate, isobutyl isovalerate, butyl stearate, pentyl stearate, methyl benzoate, ethyl benzoate, propyl benzoate, butyl benzoate, isopentyl benzoate, benzyl benzoate, ethyl cinnamate, diethyl oxalate, dibutyl oxalate, dipentyl oxalate, diethyl malonate, dimethyl maleate, diethyl maleate, dibutyl maleate, dimethyl phthalate, diethyl phthalate, dibutyl phthalate, diisobutyl phthalate, and triacetin; amines such as methylamine, dimethylamine, trimethylamine, ethylamine, diethylamine, triethylamine, propylamine, diisopropylamine, butylamine, isobutylamine, dibutylamine, tributylamine, pentylamine, dipentylamine, tripentylamine, 2-ethylhexylamine, allylamine, aniline, N-methylaniline, N,N-dimethylaniline, N,N-diethylaniline, toluidine, cyclohexylamine, dicyclohexylamine, pyrrole, piperidine, pyridine, picoline, 2,4-lutidine, 2,6-lutidine, 2,6-di(t-butyl)pyridine, quinoline, and isoquinoline; ethers such as diethyl ether, dipropyl ether, diisopropyl ether, dibutyl ether, dihexyl ether, anisole, phenetole, butyl phenyl ether, methoxytoluene, benzyl ethyl ether, diphenyl ether, dibenzyl ether, veratrole, 2-epoxypropane, dioxane, trioxane, furan, 2,5-dimethylfuran, tetrahydrofuran, tetrahydropyrane, 1,2-diethoxyethane, 1,2-dibutoxyethane, and crown ethers; ketones such as acetone, methyl ethyl ketone, methyl propyl ketone, diethyl ketone, butyl methyl ketone, methyl isobutyl ketone, methyl pentyl ketone, dipropyl ketone, diisobutyl ketone, cyclohexanone, methylcyclohexanone, and acetophenone; thioethers such as dimethyl sulfide, diethyl sulfide, thiophene, and tetrahydrothiophene; silyl ethers such as tetramethoxysilane, tetraethoxysilane, tetra(n-propoxy)silane, tetra(isopropoxy)silane, tetra(n-butoxy)silane, tetra(isopentoxy)silane, tetra(n-hexoxy)silane, tetraphenoxysilane, tetrakis(2-ethylhexoxy)silane, tetrakis(2-ethylbutoxy)silane, tetrakis(2-methoxyethoxy)silane, methyltrimethoxysilane, ethyltrimethoxysilane, n-propyltrimethoxysilane, isopropyltrimethoxysilane, n-butyltrimethoxysilane, isobutyltrimethoxysilane, sec-butyltrimethoxysilane, t-butyltrimethoxysilane, phenyltrimethoxysilane, vinyltrimethoxysilane, norbornyltrimethoxysilane, cyclohexyltrimethoxysilane, chloromethyltrimethoxysilane, 3-chloropropyltrimethoxysilane, chlorotrimethoxysilane, triethoxysilane, methyltriethoxysilane, ethyltriethoxysilane, n-propyltriethoxysilane, n-butyltriethoxysilane, phenyltriethoxysilane, vinyltriethoxysilane, 3-aminopropyltriethoxysilane, ethyltri(isopropoxy)silane, isopentyl(n-butoxy)silane, methyl(tri-n-hexoxy)silane, methyldimethoxysilane, dimethyldimethoxysilane, n-propylmethyldimethoxysilane, n-propylethyldimethoxysilane, di(n-propyl)dimethoxysilane, isopropylmethyldimethoxysilane, di (isopropyl)dimethoxysilane, n-propylisopropyldimethoxysilane, n-butylmethyldimethoxysilane, n-butylethyldimethoxysilane, n-butyl-n-propyldimethoxysilane, n-butylisopropyldimethoxysilane, di(n-butyl)dimethoxysilane, isobutylmethyldimethoxysilane, diisobutyldimethoxysilane, sec-butylethyldimethoxysilane, di(sec-butyl)dimethoxysilane, t-butylmethyldimethoxysilane, t-butyl-n-propyldimethoxysilane, di(t-butyl)dimethoxysilane, t-butyl-n-hexyldimethoxysilane, diisoamyldimethoxysilane, n-hexyl-n-propyldimethoxysilane, n-decylmethyldimethoxysilane, norbornylmethyldimethoxysilane, cyclohexylmethyldimethoxysilane, methylphenyldimethoxysilane, diphenyldimethoxysilane, dicyclopentyldimethoxysilane, dimethyldiethoxysilane, diethyldiethoxysilane, di(isopropyl)diethoxysilane, sec-butylmethyldiethoxysilane, t-butylmethyldiethoxysilane, dimethyl(n-butoxy)silane, trimethylmethoxysilane, trimethylethoxysilane, trimethylisopropoxysilane, trimethyl-n-propoxysilane, trimethyl-t-butoxysilane, trimethylisobutoxysilane, trimethyl-n-butoxysilane, trimethyl-n-pentoxysilane, and trimethylphenoxysilane; phosphines such as methylphosphine, ethylphosphine, phenylphosphine, benzylphosphine, dimethylphosphine, diethylphosphine, diphenylphosphine, methylphenylphosphine, trimethylphosphine, triethylphosphine, triphenylphosphine, tri(n-butyl)phosphine, ethylbenzylphenylphosphine, ethylbenzylbutylphosphine, trimethoxyphosphine, and diethylethoxyphosphine; phosphine oxides such as triphenylphosphine oxide, dimethylethoxyphosphine oxide, and triethoxyphosphine oxide; nitriles such as acrylonitrile, cyclohexanedinitrile, and benzonitrile; nitro compounds such as nitrobenzene, nitrotoluene, and dinitrobenzene; acetals such as acetone dimethylacetal, acetophenone dimethylacetal, benzophenone dimethylacetal, and cyclohexanone dimethylacetal; carbonate esters such as diethyl carbonate, diphenyl carbonate, and ethylene carbonate; thioacetals such as 1-ethoxy-1-(methylthio)cyclopentane and thioketones such as cyclohexanethione. The Lewis base compound is not limited thereto. The α-olefin in the present invention includes specifically ethylene, propylene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, and styrene, but is not limited thereto, and two or more thereof may be used in combination. The catalyst may be prepared in the present invention by mixing the aforementioned components of a metallocene compound (a), an ionizing ionic compound (b), an organoaluminum compound (c) and a Lewis base compound (d), for example, in an inert solvent. The method of catalyst preparation is not limited thereto. The ionizing ionic compound (b) is used in an amount of preferably not less than one mole per mole of the metallocene compound (a) in the present invention to obtain a desirable catalyst activity. Although the upper limit is not specified, the amount of the ionizing ionic compound to be used is preferably not more than 100 moles per mole of the metallocene compound in consideration of the ash content of the produced polymer, or not more than 30 moles per mole of the metallocene compound in consideration of the cost. The organic aluminum compound (c) is used in an amount of preferably not less than 10 moles per mole of the metallocene compound (a) in terms of aluminum to obtain a desirable catalyst activity, and not more than 100000 moles to suppress the chain transfer causing lowering of molecular weight and not to increase the ash content, although the amount is not limited thereto. The Lewis base compound (d) is used in an amount of preferably not less than 0.1 mole per mole of the metallocene compound (a) to stabilize the active species and to prevent loss of the catalyst activity and raise polymer productivity, and preferably not more than 1000 moles not to retard the polymerization reaction. The process for the polymerization is not specially limited, and includes slurry processes, gas phase processes, bulk processes, solution processes, and high-temperature high-pressure processes. The temperature of the polymerization is not specially limited, but is preferably not lower than 0°C to obtain high productivity, and not higher than 300°C to suppress the chain transfer causing lowering of molecular weight and maintain the catalyst efficiency. The pressure of the polymerization is not specially limited, but is preferably atmospheric pressure or higher to obtain high productivity. The present invention is described more specifically by reference to examples without limiting the invention thereto. The procedures of polymerization, reaction, and solvent purification were conducted in an inert atmosphere. The solvent used in the reaction was purified, dried, and/or deoxygenated by conventional methods. The compounds used in the reactions were synthesized and identified by conventional methods. Example 1 In a 1-liter reactor, was placed 600 ml of an aliphatic hydrocarbon (IP Solvent 1620, produced by Idemitsu Petrochemical Co.). The temperature of the reactor was maintained at 150°C. Ethylene was fed to the reactor at a pressure of 20 kg/cm 2 . Separately, a solution of 0.25 µmol of diphenylmethylene(cyclopentadienyl)(fluorenyl)zirconium dichloride in toluene was placed in another vessel, and thereto a solution of triisobutylaluminum in toluene (triisobutylaluminum: 20% by weight) was added in an amount of 62.5 µmol in terms of aluminum. The mixture was stirred for one hour. Then the mixture was added to a solution of 0.5 µmol of N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate in toluene, and the mixture was stirred for 10 minutes. To this mixture, a solution of 2.5 µmol of diisobutyl phthalate in toluene was added, and the mixture was stirred for 10 minutes. The resulting mixture was introduced into the aforementioned reactor by nitrogen pressure. The reactor was maintained at 150°C with stirring at a rate of 1500 rpm for one hour. The resulting reaction product was dried at 100°C under vacuum for 6 hours to obtain an ethylene polymer. The result is shown in Table 1. Example 2 An ethylene polymer was obtained in the same manner as in Example 1 except that 12.5 µmol of diphenyldimethoxysilane was used in place of 2.5 µmol of the diisobutyl phthalate. The result is shown in Table 1. Comparative Example 1 An ethylene polymer was obtained in the same manner as in Example 1 except that 2.5 µmol of diisobutyl phthalate was not used. The result is shown in Table 1. Example 3 In a 1-liter reactor, was placed 600 ml of an aliphatic hydrocarbon (IP Solvent 1620, produced by Idemitsu Petrochemical Co.). The temperature of the reactor was maintained at 150°C. Ethylene was fed to the reactor at a pressure of 20 kg/cm 2 . Separately, a solution of 1.0 µmol of ethylenebis(indenyl)zirconium dichloride in toluene was placed in another vessel, and thereto a solution of triisobutylaluminum (triisobutylaluminum: 20% by weight) was added in an amount of 250 µmol in terms of aluminum. The mixture was stirred for one hour. Then the mixture was added to a solution of 2 µmol of N,N-dimethylanilinium tetrakis(pentafluorophenyl)borate in toluene, and the mixture was stirred for 10 minutes. To this mixture, a solution of 50 µmol of diisobutyl phthalate in toluene was added, and the mixture was stirred for 10 minutes. The resulting mixture was introduced into the aforementioned reactor by nitrogen pressure. The reactor was maintained at 150°C with stirring at a rate of 1500 rpm for one hour. The resulting reaction product was dried at 100°C under vacuum for 6 hours to obtain an ethylene polymer. The result is shown in Table 1. Example 4 An ethylene polymer was obtained in the same manner as in Example 3 except that 10 µmol of diphenyldimethoxysilane was used in place of 50 µmol of the diisobutyl phthalate. The result is shown in Table 1. Example 5 An ethylene polymer was obtained in the same manner as in Example 3 except that 50 µmol of diphenyldimethoxysilane was used in place of 50 µmol of the diisobutyl phthalate. The result is shown in Table 1. Example 6 An ethylene polymer was obtained in the same manner as in Example 3 except that 250 µmol of diphenyldimethoxysilane was used in place of 50 µmol of the diisobutyl phthalate. The result is shown in Table 1. Comparative Example 2 An ethylene polymer was obtained in the same manner as in Example 3 except that 50 µmol of diisobutyl phthalate was not used. The result is shown in Table 1. The ionic metallocene catalyst of the present invention, as described above exhibits excellent catalytic activity in polymerization of α-olefin, and enables production of α-olefin polymer with high efficiency. Zr complex Lewis base compound LB/Zr Yield (g) Examples 1 Ph 2 C(Cp)(Flu)ZrCl 2 DIBP 10 36 2 Ph 2 C(Cp)(Flu)ZrCl 2 DPDMS 50 36 3 Et(Ind) 2 ZrCl 2 DIBP 50 64 4 Et(Ind) 2 ZrCl 2 DPDMS 10 46 5 Et(Ind) 2 ZrCl 2 DPDMS 50 40 6 Et(Ind) 2 ZrCl 2 DPDMS 250 48 Comparative Examples 1 Ph 2 C(Cp)(Flu)ZrCl 2 - - 18 2 Et(Ind) 2 ZrCl 2 - - 29 DIBP : Diisobutyl phthalate DPDMS : Diphenyldimethoxysilane

Claims: A catalyst for polymerization of olefins, comprising a) a metallocene compound, b) an ionizing ionic compound, c) organoaluminum compound, and d) a Lewis base compound: a) the metallocene compound being represented by General Formula (1) or (2): where Cp 1 , Cp 2 , Cp 3 and Cp 4 are independently a substituted or unsubstituted cyclopentadienyl, indenyl, or fluorenyl group; R 1 is a substituted or unsubstituted alkylene, dialkylsilanediyl, dialkylgermanediyl, alkylphosphinediyl, or alkylimino group, and R 1 links Cp 1 with Cp 2 by bridging; M is a titanium atom, a zirconium atom, or a hafnium atom; and R 2 , R 3 , R 4 and R 5 are independently a hydrogen atom, a halogen atom, a hydrocarbon group of 1 to 12 carbon atoms, an alkoxy group, or an aryloxy group; b) the ionizing ionic compound being a compound which is capable of changing the above a) metallocene compound into a cationic metallocene compound and does not react further with the formed cationic metallocene compound; c) the organoaluminum compound being represented by General Formula (3): where R 6 , R 6' , and R 6'' are independently a hydrogen atom, a halogen atom, an amino group, an alkyl group, an alkoxy group, or an aryl group, and at least one of R 6 , R 6' , and R 6'' is an alkyl group; d) the Lewis base compound being capable of donating an electron to the formed cationic metallocene compound. A process for producing an α-olefin polymer by polymerizing an α-olefin in the presence of the catalyst as defined in claim 1.

Inventors: HASEGAWA SAIKI, YANO AKIHIRO, YASUDA HISAMI, HASEGAWA, SAIKI, YANO, AKIHIRO, YASUDA, HISAMI
Applicants: TOSOH CORP, TOSOH CORPORATION
Application year: 1994
Main classification: C08F10
IPC codes: C08F10, C08F4